Protective device with end-of-life indication before power denial

ABSTRACT

The present invention is directed to an electrical wiring device that includes an automatic self-test assembly coupled to the plurality of line terminals or the plurality of load terminals, the detection circuit, the fault detection circuit and the circuit interrupter assembly. The automatic self-test assembly is configured to cause the detection circuit to generate a simulated sensor fault signal during a predetermined half-cycle of an AC line cycle in accordance with a predetermined periodic testing schedule, monitor the fault detection signal corresponding to the simulated sensor fault signal, and generate a test result signal based on monitoring the fault detection signal. The automatic self-test assembly also includes a noise immunized decision circuit configured to evaluate a plurality of test results to thereby provide a noise immunized end-of-life signal. One of the conductive paths that connects the plurality of line terminals and the plurality of load terminals being interrupted in response to the noise immunized end-of-life signal.

CROSS-REFERENCE TO RELATED APPLICATIONS

This is a continuation of U.S. patent application Ser. No. 11/025,509filed on Dec. 29, 2004, which is a continuation-in-part of U.S. patentapplication Ser. No. 10/868,610 filed on Jun. 15, 2004, the contents ofwhich are relied upon and incorporated herein by reference in theirentirety, and the benefit of priority under 35 U.S.C. §120 is herebyclaimed.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to electric circuit protectiondevices, and particularly to protection devices with an end-of-lifeindicator.

2. Technical Background

Examples of electric circuit protection devices include ground faultcircuit interrupters (GFCIs), arc fault circuit interrupters (AFCIs), ordevices that include both GFCIs and AFCIs in one protective device. Anelectric circuit typically includes at least one protection device. Ofcourse, an electric circuit is configured to transmit AC power from abreaker box to one or more load circuits disposed in the electriccircuit. A load circuit may include any electrically powered device suchas lighting devices, appliances, or other such devices.

The function of a protection device is to eliminate fault conditionsthat may result in shock or fire hazards. The most common faultconditions are ground faults and arc faults. Accordingly, a protectiondevice must first detect a fault condition and then remove power to theload circuit in response thereto. Protection devices employ interruptingcontacts that are opened to thereby break the connection between theprotection device's line terminals and load terminals.

An arc fault is a discharge of electricity between two or moreconductors. An arc fault may be caused by damaged insulation on the hotline conductor or neutral line conductor, or on both the hot lineconductor and the neutral line conductor. The damaged insulation maycause a low power arc between the two conductors and a fire may result.Thus, an arc fault circuit interrupter (AFCI) protects the electriccircuit in the event of an arc fault. An arc fault usually manifestsitself as a high frequency current signal characterized by a “particularsignature.” In other words, an arc fault signal typically includes aconcentration of energy in certain frequency bands. Accordingly, an AFCImay be configured to detect various high frequency signals, i.e., thesignature, and de-energize the electrical circuit in response thereto.

A ground fault is a condition that occurs when a current carrying (hot)conductor contacts ground to create an unintended current path. Theunintended current path represents an electrical shock hazard. A groundfaults may also result in fire. A ground fault may occur for severalreasons. If the wiring insulation within a load circuit becomes damaged,the hot conductor may contact ground, creating a shock hazard for auser. A ground fault may also occur when the equipment comes in contactwith water. A ground fault may also be caused by damaged insulationwithin the facility.

A ground fault creates a differential current between the hot conductorand the neutral conductor. Under normal operating conditions, thecurrent flowing in the hot conductor should equal the current in theneutral conductor. Thus, GFCIs typically compare the current in the hotconductor(s) to the return current in the neutral conductor by sensingthe differential current between the two conductors. The GFCI mayrespond by actuating an alarm and/or interrupting the circuit. Circuitinterruption is typically effected by opening the line between thesource of power and the load.

A grounded neutral condition occurs when the load neutral terminal, or aconductor connected to the load neutral terminal, becomes grounded. Thiscondition does not represent an immediate shock hazard. On the otherhand, a grounded-neutral condition is an insidious double-faultcondition that may lead to fatal consequences. Consider that a GFCI isconfigured to trip when the differential current is greater than orequal to approximately 6 mA. However, when the load neutral conductor isgrounded the GFCI becomes de-sensitized because some of the return pathcurrent is diverted to ground. When this happens, it may take up to 30mA of differential current before the GFCI trips. Thus, when both thehot conductor and the load neutral conductor are grounded, the GFCI mayfail to trip, causing a user to experience serious injury or death.

Accordingly, it is desirable to provide a protection device that iscapable of self-testing for all of the fault conditions described above.Further, a self-testing device is needed that detects the failure ofcertain components, such as the silicon controlled rectifier (SCR). If afailure mode is detected, the device is driven to a lock-out mode, suchthat power is permanently de-coupled from the load. A device is furtherneeded that alerts the user to the end-of-life condition describedimmediately above. In other words, a device that includes an end-of-lifeindication before the device is driven into lock-out would beparticularly advantageous.

SUMMARY OF THE INVENTION

The present invention addresses the needs described above. The presentinvention also provides several methods for detecting that anend-of-life condition has been reached. The protective device of thepresent invention also provides an advantageous indication that alertsthe user to the fact that device failure has occurred. The deviceprovides the user with a predetermined amount of time to replace theprotective device before the device permanently denies power to the loadterminals. The protective device permanently denies power to the loadterminals after the predetermined amount of time has elapsed.

The present invention provides a variety of methods for indicating thatan end-of-life, or device failure, has occurred. In one embodiment, theindicator is actuated automatically by a self-test mechanism thatautomatically identifies an end-of-life condition. In an another methodprovided by the present invention, the end-of-life condition is detectedby manually depressing a test button. The test button initiates a testprocedure. If the protective device fails to generate a test acceptancesignal in response to the test procedure, the indicator is energized.

In another embodiment, the end-of-life/device failure indicationprocedure may include tripping the protective device in the event thatthe end-of-life test acceptance signal is not generated by the device.While the user may be able to reset the protective device to restorepower to the load terminals, the protective device permanently deniespower to the load terminals after a predetermined period of time haselapsed.

One aspect of the present invention is directed to an electrical wiringdevice that includes an automatic self-test assembly coupled to theplurality of line terminals or the plurality of load terminals, thedetection circuit, the fault detection circuit and the circuitinterrupter assembly. The automatic self-test assembly is configured tocause the detection circuit to generate a simulated sensor fault signalduring a predetermined half-cycle of an AC line cycle in accordance witha predetermined periodic testing schedule, monitor the fault detectionsignal corresponding to the simulated sensor fault signal, and generatea test result signal based on monitoring the fault detection signal. Theautomatic self-test assembly also includes a noise immunized decisioncircuit configured to evaluate a plurality of test results to therebyprovide a noise immunized end-of-life signal. One of the conductivepaths that connects the plurality of line terminals and the plurality ofload terminals being interrupted in response to the noise immunizedend-of-life signal.

Additional features and advantages of the invention will be set forth inthe detailed description which follows, and in part will be readilyapparent to those skilled in the art from that description or recognizedby practicing the invention as described herein, including the detaileddescription which follows, the claims, as well as the appended drawings.

It is to be understood that both the foregoing general description andthe following detailed description are merely exemplary of theinvention, and are intended to provide an overview or framework forunderstanding the nature and character of the invention as it isclaimed. The accompanying drawings are included to provide a furtherunderstanding of the invention, and are incorporated in and constitute apart of this specification. The drawings illustrate various embodimentsof the invention, and together with the description serve to explain theprinciples and operation of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic of a circuit protection device in accordance withone embodiment of the present invention;

FIG. 2 is a schematic of a circuit protection device in accordance witha second embodiment of the present invention;

FIG. 3 is a schematic of a circuit protection device in accordance witha third embodiment of the present invention;

FIG. 4 shows the timing sequence for the end-of-life indication andlock-out features of the present invention;

FIG. 5 are timing diagrams illustrating the manual test features of thepresent invention;

FIG. 6 are timing diagrams illustrating the reset functionality of thepresent invention;

FIG. 7 is a schematic of a protective circuit that includes a powerdenial mechanism in accordance with the present invention;

FIG. 8 is a perspective view of the power denial mechanism shown in FIG.7;

FIG. 9 is a schematic of a circuit protection device in accordance witha fourth embodiment of the present invention;

FIG. 10, a partial sectional view of a power denial mechanism inaccordance with a fifth embodiment of the invention;

FIG. 11 shows the mechanism of FIG. 10 in the tripped state; and

FIG. 12 is a detail view of a circuit interrupter in accordance withanother embodiment of the present invention.

DETAILED DESCRIPTION

Reference will now be made in detail to the present exemplaryembodiments of the invention, examples of which are illustrated in theaccompanying drawings. Wherever possible, the same reference numberswill be used throughout the drawings to refer to the same or like parts.An exemplary embodiment of the protection device of the presentinvention is shown in FIG. 1, and is designated generally throughout byreference numeral 10.

As embodied herein, and depicted in FIG. 1, a schematic of a circuitprotection device 10 in accordance with one embodiment of the presentinvention is disclosed. GFCI 10 includes ground fault interruptercircuitry and automated self-test circuitry. An across-the-line metaloxide varistor 15 (movistor 15) may be provided to prevent damage todevice 10 from high voltage surges propagating on the line conductors11, 13. Movistor 15 is typically 12 mm in size.

The ground faulty circuitry includes a differential transformer 2 whichis configured to sense load-side ground faults. Transformer 3 isconfigured as a grounded neutral transmitter and is employed to sensegrounded-neutral fault conditions. Both differential transformer 2 andgrounded-neutral transformer 3 are coupled to detector circuit 16. Powersupply 18 provides power for GFI detector circuit 16 for full cycleoperation. Detector circuit 16 processes the transformer outputs.Detector 16 provides an output signal on output pin 20 based on thetransformer outputs. As shown in FIG. 1, the detector output signal isfiltered by circuit 21. Control gate 1116 is coupled to detector 16 andis configured to receive either detector output signal 1120 or filtereddetector output signal 20. These signals are directed into control gate1116 respectively by way of pin 12 or pin 11. Control gate 1116 directs,in turn, both of these signals into a gate circuit to thereby provideSCR 24 with a delayed output signal (SCR Out). Notice also that theoutput of by-pass circuit 1126 is likewise provided to SCR 24.Accordingly, SCR 24 may be turned ON by either a detector 16 output orby a by-pass circuit 1126 output. SCR 24 is configured to energizesolenoid 38 when it is turned ON. Solenoid 38 drives trip mechanism 73to break the circuit. When either of these signals are transmitted toSCR 24 during the negative half-cycle, SCR 24 is unable to energizesolenoid 38. However, the application of either or both of these signalsto SCR 24 does provide a test acceptance signal to the input of checkingcircuit 400.

Device 10 also includes a by-pass circuit 1126 that is coupled to sensor2. By-pass circuit 1126 represents an important safety feature that isactivated when the differential current exceeds a predetermined amount.Note that the output of by-pass 1126 is directly connected to SCR 24.Thus, when the differential current exceeds the predetermined current,control gate 1116 is by-passed and SCR 24 is actuated and device 10 istripped. The rationale for by-pass circuit 1126 is discussed below ingreater detail. Suffice it to say that in some cases it is not prudentto provide the user with a delay before tripping the device.

GFCI 10 also includes a GFI output circuit 350 formed by couplingcapacitor 40 with solenoid 38. GFI output circuit 350 links detector 16with end-of-life monitor circuit 400 and control gate 1116. Capacitor 40and solenoid 38 form a resonating tank circuit. The tank circuit isplaced in parallel with SCR 24 and a snubber circuit 35. Capacitor 40charges on the positive half cycle of the AC power, but is preventedfrom discharging on the negative half cycle of the AC power by ablocking diode 42. However, if the negative voltage across capacitor 40does not appear, it is indicative of solenoid 38 being shorted, i.e.,there is no solenoid magnetic field that exists to collapse and producethe negative voltage. Further, if any of the components includingdifferential transformer 2, GFI detector circuit 16, circuit 21, powersupply 18, SCR 24, solenoid 38, capacitor 40, and blocking diode 42 ofcircuit 102 fail, capacitor 40 will not discharge through solenoid 38,and the negative voltage across capacitor 40 from the collapsing fieldof solenoid 38 will not appear.

When the negative voltage appears across capacitor 40, the input ofend-of-life monitoring circuit 400 is driven LOW, triggering a firsttimer within end-of-life monitoring circuit 400 into a monostabletimeout mode. Accordingly, as long as the components listed above, i.e.,the differential transformer 2, GFI detector circuit 16, circuit 21,power supply 18, SCR 24, solenoid 38, capacitor 40, and blocking diode42 of circuit 102 are operating properly, capacitor 40 will beperiodically discharged to reset the first timer. As a result, the OUT 1output of circuit 400 will not signal an end-of-life condition. However,if any of these components fail, capacitor 40 will not discharge throughsolenoid 38, and the negative voltage across capacitor 40 from thecollapsing field of solenoid 38 will not appear. In this scenario, thefirst timer times out and OUT 1 signals an end-of-life condition.

In one embodiment, line 1125 and line 1127 are not connected to controlgate 1116. In this embodiment LED 1124 is illuminated to signal anend-of-life condition and a second timer included in circuit 400 isinitiated. When the second timer times out, OUT 2 turns SCR 1122 ON,current conducts through diode 42, and solenoid 38 is energized to tripcircuit interrupter 73. Those of ordinary skill in the art willrecognize that the end-of-life indicator 1124 may be implemented using avisual indication (i.e., an LED), an audible indication, or both. Onebenefit from this response method is that the user is alerted by anindication that the device has reached end-of-life. The user is thenafforded a reasonable amount of time to replace the device before powerto the load terminals becomes denied by the circuit interrupter. In oneembodiment, the pre-determined time delay is twenty-four (24) hours. Anysuitable time interval may be chosen. For example, the delay may be setat forty-eight (48) hours.

In an alternate embodiment, the end-of-life circuit includes redundancyfeatures. In this scenario, line 1125 is disposed between OUT 1 and pin10 of control gate 1116. Further, line 1127 is disposed between controlgate pin 13 and a second input of end-of-life circuit 400. A redundantLED 1140 is connected to control gate 116. The redundancy is configuredto detect and respond to an end-of-life condition in circuit 400. Theend-of-life condition in circuit 400 changes the signal on line 1127.LED 1140 is illuminated to signal the end-of-life condition and a thirdtimer, included in control gate 116, is initiated. The third timer hasthe benefit as has been described for the second timer. When the thirdtimer times out, output 13 of control gate 1116 turns SCR 24 ON, currentconducts through diode 42 and solenoid 38 is energized to trip circuitinterrupter 73. Those of ordinary skill in the art will recognize thatthe end-of-life indicator 1140 may be implemented using a visualindication (i.e., an LED), an audible indication, or both.

It will be apparent to those of ordinary skill in the pertinent art thatmodifications and variations can be made to end-of-life circuit 400depending on the configuration of output circuit 350 and/or control gate1116. For example, circuit 400 may be implemented using a singlemonolithic integrated circuit or may be implemented using discretetimers and other discrete circuit elements. For example, OUT 1 may bethe anode of an additional SCR device. Those of ordinary skill in theart will appreciate that other circuit variations are possible withinthe scope of the invention.

Control gate 1116 is coupled to detector 16 and configured to receiveeither detector output signal 1120 or filtered detector output signal20. Control gate 1116 gates these signals and provides a gated anddelayed detection signal to SCR 24 (SCR out). Control gate 1116 alsoprovides both end-of-life functionality and self-test functionality. Theself-test functionality is described as follows.

Control gate 1116 is configured to recycle between a test state and anon-test state. The durations of each of the two states are establishedby a timing circuit. Those of ordinary skill in the art will recognizethat the timing circuit may be of any suitable type. For example, thetiming circuit may be an external clocking arrangement driven by a localoscillator (not shown), a timer disposed in controller 1116, or by azero cross circuit 1117 coupled to the AC power. When control gate 1116is in the test state, it is configured to actuate self-test relay 1118during a negative half-cycle. Upon actuation, self-test relay 1118 isconfigured to actuate the self-test circuit to initiate the self-testprocedure.

Automated self-test circuit 1128 is coupled between line hot 13 and lineneutral 11. Circuit 1128 includes contacts 1130 which are disposed inseries with diode 4 and resistor 8. The self-test signal is generated byground fault simulation circuit 1128 when relay 1118 turns on to closecontacts 1130. Those of ordinary skill in the art will recognize thattest circuit 1128 may be implemented using various alternate faultsimulation circuits. For example, if control gate 1116 and self-testrelay 1118 are programmed to close contacts 1130 only during thenegative half cycle of AC power, diode 4 may be omitted. Alternatively,if contacts 1130 are configured to close for a full line cycle, diode 4should be included to limit the simulated ground fault current to thenegative half cycle. The current flowing through resistor 8 produces adifference current between the hot and neutral conductors, conductors 13and 11, which is sensed by transformer 2, in the manner previouslydescribed. Of course, the SCR 24 cannot conduct line current during thenegative half-cycle of the AC wave. However, if SCR 24 is not signaledby detector 16, the end-of-life sequence described above is initiated.

It will be apparent to those of ordinary skill in the pertinent art thatmodifications and variations can be made to control gate 1116 of thepresent invention depending on device selection and design issues. Forexample, control gate 1116 may be implemented using a microprocessor, anapplication specific integrated circuit (ASIC), or a combination ofother electronic devices familiar to those skilled in the art. In theexample shown in FIG. 1, control gate 1116 is implemented as a discretemicroprocessor component. In another embodiment, control gate 1116 iscombined in an ASIC with other device components and sub-systems. Forexample, an ASIC may include detector 16, self-test circuit 400, andother such components.

As those of ordinary skill in the pertinent art will recognize,self-test relay 1118 may be of any suitable type depending on electricaldevice characteristics. For example, relay 1118 may be implemented usingan electro-mechanical relay. Relay 1118 may also be implemented using asolid state switches such as a thyristor, SCR, triac, transistor,MOSFET, or other semiconductor devices.

The operation of control gate 1116 is now described in more detail.During recurring non-test state intervals, the detector output signal20, or 1120, is directed to control gate 1116, as previously described.When control gate 1116 is in the non-test state, control gate 1116de-activates the negative half cycle self-test signal by turning offself-test relay 1118, permitting detection of the true fault signalwhile avoiding the self-test signal interference. In this state, GFI 10may detect a true fault signal in either half cycle, but is responsiveto the fault only in the positive half cycles. The duration of thenon-test state intervals may be selected within a time range between one(1) second and one (1) month. One month is typically considered as beingthe maximum safe interval between tests. In one embodiment, the durationof the non-test state interval is about one minute. The test/non-testcycle is recurring; each non-test cycle is followed by a test statecycle, and each test cycle is followed by a non-test state cycle.

Accordingly, GFI 10 is in a self-test mode during the test stateinterval. In one embodiment, a self-test signal is transmitted duringthe first negative half cycle in the test state interval. In anotherembodiment, the simulated test is effected in selected negativehalf-cycles, or in each negative half-cycle in the test interval. In thecircuit example depicted in FIG. 1, control gate 1116 activatessimulated fault signal during a negative half cycle by turning onself-test relay 1118. The simulated test signal causes detector 16 toproduce a signal at output 20 or at an alternate output 1120 during eachnegative half-cycle. Output 1120 provides the same information as output20, but is configured to generate digital logic levels. Control gate1116 gates the detector 16 output signal received during the negativehalf cycle to SCR 24. The gate functions to block any extended signalfor a predetermined amount of time after the negative half cycle.

The predetermined time interval is chosen such that any remainingextended signal is substantially less than the expected true faultsignal. The predetermined interval is typically set at 30 to 50milliseconds. As a result, any self-test signal that extends beyond thenegative half cycle does not cause false activation of SCR 24. However,the portion of the test acceptance signal propagating during thenegative half cycles will cause the timer in ring detector 400 to reset.With regard to the predetermined time interval, by-pass circuit 1126 isprovided to allow device 10 to respond in accordance with UL trip timerequirements if a true fault condition occurs during the 30 to 50millisecond dead period described above.

With regard to device 10 testing, the various embodiments of the devicemay be equipped with a manually accessible test button 1132 for closingswitch contacts 1134 for initiating a simulated grounded hot faultsignal, as current through resistor 1136, or alternatively, a simulatedgrounded neutral fault signal (not shown.) If GFI 10 is operational,closure of switch contacts 1134 initiates a tripping action. The purposeof the test button feature may be to allow the user to control GFCI 10as a switch for applying or removing power from load 1106 connected todevice 10, in which case test button 1132 and reset button 75 have beenlabeled “off” and “on” respectively. Usage of test button 1132 does notaffect the performance of the ability to detect and respond to anend-of-life condition, or vice-versa.

Referring back to by-pass circuit 1126, by-pass circuit 1126 isconfigured to circumvent control gate 1116 under certain circumstances.In the event of a ground fault, the operation of control gate 1116 maybe delayed by capacitive charging time constants in power supply 18 andby delays in control gate 1116, including software-related delays. Thesedelays might prevent trip mechanism 73 from interrupting high amplitudeground fault currents greater than about 100 mA within known safemaximum time limits.

This trip time requirement is provided in UL 943. UL 943 includes aninverse time-current curve: t=(20/I )^(1.43) where “I” is the faultcurrent in milliamps (mA) and “t” is the trip time in seconds. Typicalvalues for the fault current range between 6 mA and 264 mA. The 6 mAcurrent is the “let-go threshold.” In other words, UL does not considercurrents less than 6 mA to be a hazard. The 264 mA limit corresponds to132 VAC (the maximum source voltage) divided by 500 Ohms (the least bodyresistance for a human being). Applying the trip time curve, a 6 mAfault current is allowed a maximum trip time of 5 seconds. A 264 mAfault current is allowed a maximum trip time of 0.025 seconds. By-passcircuit 1126 is configured to actuate SCR 24 when the fault currentexceeds 100 mA. According to the trip time curve, if the fault currentequals 100 mA, the calculated trip time is 0.1 seconds (100milliseconds.) Thus, the 30 to 50 millisecond dead period does notviolate the UL trip time curve for true ground faults below 100 mA. Fortrue fault currents above 100 mA, bypass circuit 1126 overrides the deadperiod lock-out. Accordingly, the present invention is in accordancewith UL trip time requirements. Those of ordinary skill in the art willrecognize that bypass circuit 1126 and detector 16 may be combined in asingle monolithic integrated circuit.

Another feature of the present invention relates to noise immunity. Thesources of transient noise include switching noise from the AC powersource, electrical noise associated with loads having commutating motorswith brushes, or the noise associated with various kinds of lamps orappliances. Noise immunity is a consideration because transient noisemay interfere with the self-test signal. Under certain circumstances,noise may interfere with, or cancel, the self-test signal. Accordingly,the timer in circuit 400 may not be reset despite the fact that there isno internal fault condition in GFCI 10. Accordingly, in one embodimentthe timer in circuit 400 is programmed to measure a time interval thatspans four simulated test cycles, or a predetermined amount of time,such as four minutes, for example. Thus, circuit 400 need only detectone in four test acceptance signals during the time interval for timerreset. It is unlikely that a transient noise event would disturb eitherfour consecutive negative half cycles or last for a period of 4 minutes.As such, programming the timer in this manner desensitizes GFCI 10 tothe effects of transient electrical noise.

As embodied herein and depicted in FIG. 2, a schematic of a circuitprotection device in accordance with a second embodiment of the presentinvention is disclosed. FIG. 2 is a schematic diagram of an alternateembodiment in which the fault simulation circuit generates a simulatednegative half cycle grounded neutral signal. Reference is made to U.S.patent application Ser. No. 10/768,530, which is incorporated herein byreference as though fully set forth in its entirety, for a more detailedexplanation of the fault simulation signal. Note that test circuit 1128does not include diode 4.

The GFI circuit 102 in FIG. 2 includes a transformer 2 that isconfigured to sense a load-side ground fault when there is a differencein current between the hot and neutral conductors. Transformer 2transmits a sensed signal to detector circuit 16. GFI circuit 102 alsoincludes a grounded neutral transmitter 3 that is configured to detectgrounded neutral conditions. Those skilled in the art understand thatthe conductor connected to neutral line terminal 11 is deliberatelygrounded in the electrical circuit. On the other hand, a groundedneutral condition occurs when a conductor connected to load neutralterminal 1110 is accidentally grounded.

The grounded neutral condition creates a parallel conductive path withthe return path disposed between load terminal 1110 and line terminal11. When a grounded neutral condition is not present, grounded neutraltransmitter 3 is configured to couple equal signals into the hot andneutral conductors. As noted above, transformer 2 senses a currentdifferential. Thus, when no fault condition exists, the current flowingin the hot conductor cancels the current flowing in the neutralconductor. However, when a grounded neutral condition is present, thesignal coupled onto the neutral conductor circulates as a current aroundthe parallel conductive path and the return path, forming a conductiveloop which is simulated by conductive loop 1212. Since the circulatingcurrent propagates through the neutral conductor but not the hotconductor, a differential current is generated. Transformer 2 detectsthe differential current between the hot and neutral conductors. Assuch, detector 16 produces a signal on output 20 in response to thegrounded neutral condition.

In one embodiment, ground fault detector 16 is implemented using an RV4141 integrated circuit manufactured by Fairchild Semiconductor. Thoseof ordinary skill in the art will understand that any suitable devicemay be employed herein. Transformer 2 may be implemented using atoroidally shaped magnetic core 1102 about which a winding 1104 iswound. Winding 1104 is coupled to an input terminal 1202 of ground faultdetector 16. Winding 1104 typically has 1,000 turns. Grounded neutraltransmitter 3 may be implemented using a second toroidally shapedmagnetic core 1204 about which a winding 1206 is wound. Winding 1206 iscoupled in series with a capacitor 1208 to the gain output terminal 1210of ground fault detector 16. Winding 1206 typically has 200 turns. Hotand neutral conductors 13 and 11 pass through the apertures of cores1102 and 1204.

During a grounded neutral condition, low level electrical noiseindigenous to the electrical circuit or to ground fault detector 16creates a magnetic flux in either core 1102 or 1204, or both. The fluxin core 1204 is induced by winding 1206. Core 1204 induces a circulatingcurrent in electrical loop 1212, which induces a flux in core 1102. Theresulting signal from winding 1104 is amplified by the gain of groundfault detector 16 to produce an even greater flux in core 1204 viawinding 1206. Because of this regenerative feedback action, ground faultdetector 16 breaks into oscillation. The frequency typically is in arange between 5 kHz and 10 kHz. This oscillation produces a signal onoutput 20. Control gate 1116 ultimately signals SCR 24 to trip thedevice 10.

Electrical loop 1212 is part of the fault simulation circuit 1128. Loop1212 has a resistance associated with it; the resistance is shown inFIG. 2 as lumped resistance 1214. Resistance 1214 is typically less than2 Ohms. Electrical loop 1212 couples the grounded neutral transmitter 3and ground fault detector 2 when contacts 1130 are closed during atleast first negative half cycle of each test state interval.Accordingly, a simulated grounded neutral condition is generated onlyduring the negative half cycle. The simulated grounded neutral conditioncauses detector 16 to generate a fault detect output signal on line 20to retrigger the timer in ring detector 400 during test state intervals.Absence of the timer reset signal indicates that the device has reachedits end of life. As previously discussed, the end of life conditioncauses activation of an end of life indicator, tripping of interruptingcontacts, or both.

Again, the various embodiments of the device may be equipped with amanually accessible test button 1132 configured to close switch contacts1134. Upon closure of contacts 1134, current flows through resistor 1136and a simulated grounded hot fault signal is initiated. In anotherembodiment, a simulated grounded neutral fault signal (not shown) isinitiated by actuating test button 1132. If GFI 10 is operational,closure of switch contacts 1134 initiates a tripping action. The purposeof the test button feature may be to allow the user to control GFCI 10as a switch for applying or removing power from load 1106. As such, testbutton 1132 and reset button 75 may be labeled “off” and “on,”respectively. Usage of test button 1132 does not affect the ability todetect and respond to an end-of-life condition. or vice-versa.

The GFI output circuit 350, circuit 400, and control gate 1116 aresimilar, if not identical, to those depicted in FIG. 1.

As embodied herein and depicted in FIG. 3, a schematic of a circuitprotection device in accordance with a third embodiment of the presentinvention is disclosed. FIG. 3 is a schematic diagram that illustrateshow the present invention may be applied to a general protective device300. Further, FIG. 3 incorporates a redundant solenoid.

If sensor 1302 is included, the protective device is an AFCI. Iftransformers 2 and 3 are included, the protective device is a GFCI. Ifsensor 1302, and transformers 2 and 3 are included, the protectivedevice is a combination AFCI-GFCI. Stated generally, the protectivedevice may include one or more, or a combination of sensors configuredto sense one or more type of hazardous conditions in the load, or in theAC electrical circuit supplying power to the load. Sensor 1302 senses anarc fault signature in load current. Detector 1304 is similar to groundfault detector 16, but is configured to detect signals from any of thevariety of sensors employed in the design. Detector may also provide asignal to a transmitter, such as transformer 3.

Fault simulation circuit 1306 is similar to fault simulation circuit1128 but configured to produce one or more simulation signal to confirmthat the protective device is operational. Contacts 1130 are closed byoperation of relay 1118 during a test state interval. Fault simulationsignals are generated during negative half cycles of AC power. Theembodiment of FIG. 3 is similar to the previous embodiments discussedherein, in that any extended test fault signals from fault detector 1304to SCR 24 are blocked by control gate 1116. In this manner, simulationsignals that extend into positive half cycles of the AC power line donot result SCR 24 being turned ON. Accordingly, false actuations of thecircuit interrupter are prevented.

Other features and benefits can be added to the various embodiments ofthe invention. GFCI 10 may be equipped with a miswiring detectionfeature such as miswire network 1308. Reference is made to U.S. Pat. No.6,522,510, which is incorporated herein by reference as though fully setforth in its entirety, for a more detailed explanation of miswirenetwork 1308.

Briefly stated, miswire network 1308 is configured to produce asimulated ground fault condition. During the installation of protectivedevice 300 if the power source voltage is coupled to the line terminals11 and 13 as intended, the current through network 1308 causes theprotective device to trip. However, the current through network 1308continues to flow until a fusible component in network 1308 opencircuits due to I²R heating. The fusible component may be implemented byresistor 1310, which is configured to fuse in typically 1 to 10 seconds.The protective device 300 may be reset after the fusible componentopens. Subsequently, the protective device 300 and checking circuit 400operate in the previously described manner. However, when the device ismiswired by connecting the power source to the load terminals 1108 and1110 during installation, GFI 102 trips the interrupting contacts 74before the fusible component opens. The current flow through network1308 is terminated in less than 0.1 seconds. This time period is toobrief an interval to cause the fusible component to fail. Thus, whenprotective device 300 is miswired, the fusible element in network 1308remains intact. Accordingly, reset button 75 cannot effect a resettingaction. Protective device 300 cannot be reset regardless of signals toor from checking circuit 400.

As discussed above and shown in earlier embodiments, an across-the-linemetal oxide varistor (MOV), also commonly referred to as a movistor, maybe included in the protective device to prevent damage of the protectivedevice from high voltage surges from the AC power source. The movistoris typically 12 mm in size. Alternatively, a much smaller MOV may beemployed in the circuit when it is coupled with an inductance.

In this embodiment, MOV 15′ is coupled with solenoid 38. The value ofthe inductive reactance of solenoid 38 is typically greater than 50 Ohmsat the frequency of the surge voltage. The inductive reactance serves toreduce the surge current absorbed by the movistor, permitting MOV 15′ tohave a lower energy rating. Accordingly, the size of the movistor may bereduced to a 5 mm diameter device. Further, the MOV may be replacedaltogether by a surge-absorbing capacitor, air gap, or any of othersurge protection methods familiar to those who are skilled in the art.

Protective device 300 may also include a trip indicator 1312. Indicator1312 is configured to illuminate a trip indication, and/or audiblyannunciate a trip indication, when protective device 300 is tripped.Trip indicator 1312 also functions to direct the user to the location ofthe tripped device.

Another feature of the embodiment shown in FIG. 3 relates to theredundant solenoid design. Upon reaching end-of-life, solenoid 38typically fails by developing an open circuit condition. Solenoid 1314may be added to provide redundancy. If solenoid 38 open circuits,secondary 401 does not receive self-test signal. However, circuit 400 isable to trip out the protective device by actuating redundant solenoid1314. Solenoid 1314 may be magnetically coupled to solenoid 38. Otherredundancies may be included in device 300. Redundant components permitthe protective device and/or permit circuit 400 to function. Forexample, diode 1316 included in power supply 18 can comprise two diodesin parallel, such that if one diode open circuits, that second diodecontinues to maintain supply voltage.

Referring to FIGS. 4-6 are directed to timing diagrams that illustratedifferent methods for indicating the end-of-life condition before poweris permanently denied to the load terminals of the device. The timingdiagrams illustrate a method for providing a user with an end-of-lifeindication before power is permanently denied to the load byinterrupting the device contacts in a non-resettable way.

FIG. 4 shows the timing sequence for end-of-life indication andlock-out. As described above, self-testing occurs periodically on thenegative half-cycle of AC power. As such, signal “a” represents therecurring test acceptance signals from the GFI portion of device 10,i.e., the input to end-of-life monitor circuit 400. The second signal(b) represents the first timer in circuit 400. At time 1612 one of thecomponents listed above fails, representing an end-of-life condition.Accordingly, the last input pulse 1610 is received by circuit 400 attime 1614. An end-of-life condition occurs at time 1618 when the firsttimer time-out occurs. In other words, if a test acceptance signal isnot detected within time interval 1616, an end-of life signal 1618 isgenerated by the first timer. Signal (c) represents end-of-lifeindicator 1124. Pulses 1620 indicate that LED 1124 (or an audibleindicator) may be pulsed to provide a blinking light or a periodicbeeping sound. Alternatively, LED 1124 may be illuminated continuously.In another embodiment, an end-of-life indicator 1140 may be connected toreceive signal from control gate 1116 (See FIG. 1 and FIG. 2). Controlgate 1116 is configured to generate an intermittent signal to indicator1140 when an end-of-life condition has been detected. Signal (d)represents a lock-out signal such as signal OUT 2 from circuit 400, orSCR OUT from gate 1116. Lock-out signal (d) is generated following thepredetermined amount of time 1622 established by a second timer. Asshown, signal (d) generates a lock-out pulse 1624 that permanentlydisconnects the load terminals from the line terminals of device 10(300.) Those skilled in the art will recognize that signal (d) may beconfigured as an active LOW signal, as shown in FIG. 1 and/or FIG. 2.

In one embodiment of the present invention lock-out pulse 1624 isoperative to trip the trip mechanism 73. In another embodiment, aseparate set of redundant end-of-life contacts are provided. In thiscase, lock-out pulse 1624 is operative to separate the redundant contactstructure. The redundant structure may not rely on the state (i.e.,reset or tripped) of trip mechanism 73. In yet another embodiment, anend-of-life indication signal 1628 may be included for continuing toenergize the end-of-life indicator 1124 (1140) after lock-out hasoccurred. The continued blinking light, or beeping noise, helps the userlocate the failed device causing loss of power.

Referring to FIG. 5, timing diagrams illustrating the manual testfeatures of the present invention are provided. Signal (a) representsthe manual test circuit. Pulse 1710 is generated by manual actuation ofthe test button 1132. Signal (b) represents test acceptance signal 1712.Note that test acceptance signal 1712, in this case, is generated bydetector 16 and output circuit 350 within a test acceptance interval1714, indicating that protective device 10 is operational. Pulse 1718represents another manual actuation of the test button 1132. However, inthis case there is an end-of-life condition as evidenced by a lack ofany test acceptance signal 1712 within test acceptance interval 1714′.Accordingly, end-of-life signal 1618 is again generated. Signal (c)represents the operation of the end-of-life indicator 1124 (1140.)Signals 1720 and 1726 are similar to signals 1620, 1628 that have beenpreviously described. Signal (d) represents the lock-out signal 1724that is generated after predetermined amount of time 1722 elapses.Lock-out signal 1724 permanently disconnects the line terminals ofdevice 10 (300) from the line terminals.

FIG. 6 is directed to an embodiment of the invention that includes areset capability. Signal (a) represents the test acceptance signals1810. Again, test acceptance signals indicate that protective device 10(300) is operative to sense, detect, and protect device 10 for at leastone of the intended predetermined conditions. At time 1812 one of theabove listed components fail and in response, the last test acceptancesignal is transmitted at time 1814. Signal (b) refers to SCR OUT or anoutput of circuit 400. If a test acceptance signal is not detectedwithin time interval 1816, pulse 1818 is generated, directing tripmechanism 73 to trip. The falling edge of pulse 1818 corresponds to auser manually depressing the reset button 75 (FIG. 1). Signal (c)represents the output of visual indicator 1124 (or an audibleindicator). Once the user resets device 10 (300), indicator 1124 beginsto blink indicating that an end-of-life condition has occurred. Apredetermined time interval 1824 is initiated when the trip mechanism 73is reset. After time interval 1824 elapses, lock-out pulse 1826 isgenerated by either control gate 1116 or circuit 400 in the mannerpreviously described. As a result, trip mechanism 73 permanently tripsat the rising edge of pulse 1826, when the predetermined time interval1824 has expired. In reference to indicator signal (c), an ongoingindicator signal 1830 may be provided to continually energize end-oflife indicator 1124 (1140) after the predetermined time interval 1824for the reasons previously provided.

Should a test acceptance signal be generated during time interval 1622(1722, 1824), control gate 1116 and/or circuit 400 may be configured toignore the test acceptance signal. Accordingly, device 10 (300) tripswhen the predetermined time delay has elapsed in the manner previouslydescribed. In an alternate embodiment, control gate 1116 and/or circuit400 may be configured or programmed to recognize the test acceptancesignal.

If the test acceptance signal is recognized, the end-of-life signal andthe lock-out signal are both cancelled. This is another noise immunityfeature of the present invention. If noise on the electricaldistribution system momentarily defeats the recurring test signal,device 10 may recover, preventing an erroneous end-of-life lock-out tooccur. Alternatively, a “wait delay” may be included between theexpiration of interval 1616 (1714, 1816) and the onset of interval 1622(1722, 1824). In this manner, circuit 400 generates an end-of-lifesignal as before, but the end of life indicator 1124, (1140) is notenergized until the wait delay elapses. Power denial may be delayed by24 to 48 hours after an end-of-life condition is detected (thepredetermined amount of time.) Activation of the indicator may bedelayed by 5 seconds to 5 hours after an end-of-life condition isdetected (the wait delay interval.)

The user is made aware of the end-of-life condition by the end-of-lifeindicator, after which the user is given a predetermined amount of timebefore power is denied to the load terminals. In yet anotheralternative, device 10 (300) includes a counter responsive to the resetbutton. After an end-of-life condition has occurred, the counter allotsthe user a predetermined number of reset cycles before power ispermanently denied to the load terminals. During each reset cycle, thereset button enables the line terminals to be connected to the loadterminals but only for a predetermined period of time. As such, eachreset cycle serves to remind the user of the end-of-life condition. Thereset cycles may be of decreasing duration as further incentive toreplace the device before power to the load terminals becomespermanently denied.

Those of ordinary skill in the art will recognize that the timingintervals depicted in the timing diagrams may be altered and modifiedwithin the scope of the present invention. Visual indicators may be ofvarious colors or flashing patterns so as to be distinguishable fromother types of indicators included in device 10 (300), such as a tripindicator 1312, or a pilot light configured to illuminate when power isapplied to the load terminals (not shown). Two or more types ofindicators may be configured to emit light from the same location in thehousing of device 10 (300.) Visual or audible indicators may progressthrough various patterns, sounds, or colors that serve to increasinglydraw attention of the user to the impending lock-out condition.

FIGS. 7-9 depict alternate embodiments for denying power after anend-of-life condition has occurred. The embodiments that have beendescribed include a redundant solenoid such that if the trip solenoidassociated with the protective device circuit experiences an end-of-lifecondition, the redundant solenoid assures that power is denied to theload terminals. Alternatively, the trip mechanism itself may have anend-of-life condition. The checking circuit identifies the condition andproceeds to enable the indicator and a power denial mechanism. The powerdenial mechanism is configured to operate substantially independentlyfrom the trip mechanism, whether the trip mechanism is in the tripped orreset states.

As embodied herein and depicted in FIG. 7, a protective circuit 10 thatincludes a power denial mechanism is disclosed. Power denial mechanism1910 includes parallel resistors 1912, 1914 and SCR 1916 coupled betweenthe line terminals 11, 13. Resistors 1912, 1914 are configured to heatto a temperature greater than a pre-established temperature thresholdwhen device 10 (300) has an internal fault. When the temperature ofresistors 1912, 1914 is greater than the threshold, the line terminals11, 13 decouple from the feed-through load terminals 1108, 1110, andreceptacle load terminals 1108′, 1110′. Because resistors 1912, 1914 aredisposed in parallel, they heat independently. Dashed line 1922indicates that resistor 1912 is configured to open contact 1918 when thetemperature exceeds the threshold value. Likewise, dashed line 1924indicates that resistor 1914 is configured to open contact 1920 when thetemperature exceeds the threshold value. In another embodiment of thepresent invention, a single resistor can be configured to heat and opencontacts 1918 and 1920.

Power denial mechanism 1910 operates as follows. When the predeterminedamount of time described above elapses, control gate 1116 generates anoutput signal to turn SCR 1916 ON. The resulting current throughresistors 1912, 1914 causes the temperature of each resistor to begreater than the threshold, whereupon end-of-life contacts 1918, 1920are opened. The end-of-life contacts open irrespective of the operablecondition of trip mechanism 73, disconnecting the load terminals fromthe line terminals.

Referring to FIG. 8, a perspective view of the power denial mechanism1910 shown schematically in FIG. 7 is depicted. Resistors 1912 and 1914are soldered to the underside of a printed circuit board (PCB) 2010.Openings 2012 are disposed in PCB 2010 in alignment with resistors 1912and 1914. Resistors 1912 and 1914 prevent spring loaded plungers 2014from extending through the openings 2012 in board 2010. Each plunger2014 is configured to support an electrically connecting bus-bar member2016. Each bus-bar 2016 couples a line terminal (11,13) to at least oneload terminal (1108, 1108′, 1110, 1110′.) As described above, when thesolder supporting 1912 and 1914 melts, spring loaded plungers 2014 aredriven through the holes 2012, breaking the connections between the lineand the load terminals. Once this occurs, there is no mechanism forresetting the device. Accordingly, the device must be replaced.

As embodied herein and depicted in FIG. 9, a schematic of a circuitprotection device in accordance with a fourth embodiment of the presentinvention is disclosed. GFCI 10 includes a GFI circuit 102 and a selftest checking circuit 2110. GFI circuit 102 includes a standard GFCIdevice in which a load-side ground fault is sensed by a differentialtransformer 2. A transformer 3, which is a grounded neutral transmitter,is used to sense grounded neutral faults. The transformer 2 output isprocessed by a GFI detector circuit 16 which produces a signal on output20 that, after filtering in a circuit 21, activates a trip SCR 24. WhenSCR 24 turns ON, it activates a solenoid 38 which in turn operates amouse trap device 73, releasing a plurality of contacts 74 andinterrupting the load.

An across-the-line metal oxide varistor (MOV1), also commonly referredto as a movistor, may be included in the protective device such as MOV15 to prevent damage of the protective device from high voltage surgesfrom the AC power source. The movistor is typically 12 mm in size.

A power supply 18 provides power for GFI detector circuit 16 for fullcycle operation. A negative cycle bypass circuit 5, which preferablyincludes a diode 4 in series with a resistor 8, introduces a bypasscurrent, simulating a ground fault, between neutral and hot lines 11, 13during the negative half cycle of the AC power. The same bypass currentcould also be produced by placing bypass circuit 5 between lines 11 and13 with the diode 4 anode at neutral line 11.

The GFI 102 output circuit is formed by placing capacitor 40 in serieswith solenoid 38 to thereby form a resonating tank circuit. The tankcircuit is placed in parallel with SCR 24 and a snubber circuit 35.Capacitor 40 charges on the positive half cycle of the AC power, but isprevented from discharging on the negative half cycle of the AC power bya blocking diode 42.

In this embodiment, both the end-of-life checking circuit and thecontrol gate are embodied in a single component, control gate 2110.Control gate 2110 is coupled to a power denial mechanism 1910, which isconfigured to operate as follows.

The user pushes the TEST button 1132 when the device is in the resetstate to simulate a fault. The fault is introduced through resistor1136. Although the simulated fault is shown as a ground fault, an arcfault simulation could have been chosen. The present invention isequally applicable to GFCI, AFCI, or GFCI/AFCI devices. Control gate2110 is similar to control gate 1116. However, gate 2110 includes aninput 2112 coupled to the test button 1132. When test button 1132 isdepressed, control gate 2110 energizes indicator 1124 (1140). If thecomponents in GFI 102 are operative, i.e., sensor 1102, detector 16, SCR24, and trip mechanism 73, the device operates normally, and tripmechanism 73 is tripped. In response, power is removed from control gate2110 and the indicator 1124 (1140) is de-energized.

However, if one of the components in GFI 102 is inoperative, i.e., hasreached an end-of-life condition, indicator 1124 (1140) emits a visualor audible signal for at least the predetermined amount of time in themanner previously described. After the predetermined amount of time haselapsed, control gate 2110 actuates the power denial mechanism 1910,again, in the manner previously described.

In another embodiment, power denial mechanism 1910 is omitted, and SCR1916 operates breaker coil 38 or independent solenoid 1314 (See FIG. 3)to permanently disconnect the line terminals from the load terminals.

As embodied herein and depicted in FIG. 10, a partial sectional view ofa power denial mechanism in accordance with a fifth embodiment of theinvention is disclosed. Power denial mechanism 2200 is similar infunction to the embodiments depicted in FIG. 3 and FIG. 7 because it isconfigured to deny power to a load in the event of trip solenoid 38reaching an end-of-life condition.

In particular, FIG. 10 shows trip mechanism 73 in the reset position,meaning that contacts 2204 and 2206 are closed. Contacts 2204 and 2206are held closed by action of a trapped make-force spring 2208. Spring2208 acts on escapement 2210, on a reset stem 2212, to lift a resetlatch 2214 and by interference, an armature 2216. Reset latch 2214includes a hole 2218. Armature 2216 includes a hole 2219. Holes 2218 and2219 permits entry of a tip 2222 of reset stem 2212. Reset stem 2212 isheld in place by a block 2224. Armature 2216 and a printed circuit board(PCB) 2226 are mechanically referenced to a housing 2228 so that theforce in spring 2208 is concentrated into armature 2216. Electricalcomponents associated with the circuit diagram shown in the variousembodiments of the invention may be disposed on circuit board (PCB)2226.

Resistor 1912 is designed to develop a temperature greater than apredetermined threshold when device 10 (300) develops an end-of-lifecondition. Resistor 1912 is physically positioned to restrain lockoutspring 2202. Resistor 1912 (1914) is preferably mounted and soldered sothat the body of resistor 1912 (1914) impedes movement of lockout spring2202.

Referring to FIG. 11, shows the mechanism of FIG. 10 in the trippedstate. The tripped state occurs when SCR 24 activates a magnetic fieldin solenoid 38, which in turn pulls in plunger 2230 to displace resetlatch 2214. Displacing reset latch 2214 allows a flat portion to clearthe latch spring interference, which then releases the interferencebetween latch spring 2214 and armature 2216. Armature 2216 has a memorywhich returns armature 2216 to a resting position against solenoid 38,opening contacts 2204 and 2206 and disconnecting power to the load. Theprinciples shown in FIGS. 10-11 are adaptable to any number ofmechanical configurations.

Resetting is accomplished by applying a downward force on the useraccessible reset button 75. When downward force is applied, escapement2210 is reinserted through hole 2218 in latch 2214. Latch 2214 movesopposite to the direction shown. When downward force is removed,escapement 2210 is re-aligned to lift armature 2216 as has beendescribed. Thus, tripping is accomplished when plunger 2230 moves in thedirection shown to displace the position of latch 2214. Resetting isaccomplished by applying and removing force to reset button 75.

FIG. 11 also demonstrates a second mode of tripping of trip mechanism 73that is not resettable after an end-of-life condition has occurred. Theprotective device (such as GFI 102) has failed in some manner so as tobe non-responsive to a predetermined condition. Power denial mechanism2200 includes circuitry that operates in a similar manner to circuitryin mechanism 1910 when there is an end-of-life condition. Resistor 1912,no longer restrained by the solder, or in an alternative embodiment byan adhesive, is physically dislodged by the bias of lockout spring 2202.Lockout spring 2202 includes a surface 2203 that permanently displaceslatch 2214 in the direction shown. Latch 2214 cannot be aligned to theescapement 2210 even if reset button 73 is actuated. Thus, thedisplacement of resistor 1912 serves to permanently trip the tripmechanism. The permanent disconnection of the load terminals from theline terminals requires that the device be replaced.

Referring to FIG. 12, an alternate circuit interrupter is described. Thecircuit interrupter includes trip mechanism 1506, interrupting contacts1508 and reset button 1510 that are similar to previously describedelement designated as reference elements 73, 74 and 75. The circuitinterrupter is coupled to line conductors 11 and 13 and is configured todecouple one or more loads from the utility source when a true faultcondition or a simulated fault condition has been detected, or when anautomated self-test signal has failed. In particular, when decouplingoccurs there is a plurality of air gaps 1512 that serve to electricallyisolate a plurality of load structures from one another. The load mayinclude, for example, feed-through terminals 1514 that are disposed inthe protective device. The feed through terminals are configured toconnect wires to a subsequent portion of the branch electrical circuit.The portion of the branch circuit, in turn, is protected by theprotective device. The load structures can also include at least oneuser accessible plug receptacle 1516 disposed in the protective device.The plug receptacle is configured to mate with an attachment plug of auser attachable load. Accordingly, the user load is likewise protectedby the protective device.

As has been previously described, if the device 10 is inadvertentlymiswired during installation into the branch electrical circuit, i.e.,source voltage is connected to the feed-through terminals 1514, theprotective device can be configured so as to only momentarily reset eachtime resetting is attempted, e.g. each time the reset button 1510 isdepressed. Alternatively, the protective device can be configured sothat during a miswired condition, the ability to reset the device 10(1300) is blocked. In either case, air gap(s) 1512 prevent power fromthe utility source at feed-through terminals 1514 from powering plugreceptacle(s) 1516. At least one air gap 1512 can be provided for eachutility source hot conductor. The user is protected from a faultcondition in the user attachable load. Alternatively, at least one airgap 1512 can be provided but in a single utility source conductor. Powerto receptacle 1516 would be denied. Therefore the user would bemotivated to remedy the miswired condition before a fault condition islikely to arise. In yet another alternative, utility source conductorsmay selectively include air gaps 1512 for electrically decoupling theload structures.

The use of the terms “a” and “an” and “the” and similar referents in thecontext of describing the invention (especially in the context of thefollowing claims) are to be construed to cover both the singular and theplural, unless otherwise indicated herein or clearly contradicted bycontext. The terms “comprising,” “having,” “including,” and “containing”are to be construed as open-ended terms (i.e., meaning “including, butnot limited to,”) unless otherwise noted. The term “connected” is to beconstrued as partly or wholly contained within, attached to, or joinedtogether, even if there is something intervening.

The recitation of ranges of values herein are merely intended to serveas a shorthand method of referring individually to each separate valuefalling within the range, unless otherwise indicated herein, and eachseparate value is incorporated into the specification as if it wereindividually recited herein.

All methods described herein can be performed in any suitable orderunless otherwise indicated herein or otherwise clearly contradicted bycontext. The use of any and all examples, or exemplary language (e.g.,“such as”) provided herein, is intended merely to better illuminateembodiments of the invention and does not impose a limitation on thescope of the invention unless otherwise claimed.

No language in the specification should be construed as indicating anynon-claimed element as essential to the practice of the invention.

It will be apparent to those skilled in the art that variousmodifications and variations can be made to the present inventionwithout departing from the spirit and scope of the invention. There isno intention to limit the invention to the specific form or formsdisclosed, but on the contrary, the intention is to cover allmodifications, alternative constructions, and equivalents falling withinthe spirit and scope of the invention, as defined in the appendedclaims. Thus, it is intended that the present invention cover themodifications and variations of this invention provided they come withinthe scope of the appended claims and their equivalents.

1. An electrical wiring device comprising: a plurality of line terminalsand a plurality of load terminals; a sensor circuit coupled to theplurality of line terminals, the sensor circuit being configured togenerate a sensor fault signal in response to at least one faultcondition propagating on the plurality of line terminals and/or theplurality of load terminals; a fault detection circuit coupled to thesensor circuit, the fault detection circuit being configured to generatea fault detection signal when the sensor fault signal exceeds apredetermined level; a circuit interrupter assembly coupled to the faultdetection circuit, the circuit interrupter assembly including a set ofmovable contacts configured to be driven into a tripped state inresponse to the fault detection signal and driven into a reset state inresponse to a reset actuation; and an automatic self-test assemblycoupled to the plurality of line terminals or the plurality of loadterminals, the sensor circuit, the fault detection circuit and thecircuit interrupter assembly, the automatic self-test assemblyincluding, a control circuit configured to operate in a self test modeand in a non-self test mode in accordance with a predetermined schedule,the control circuit being configured to generate a self test actuationsignal during a predetermined half-cycle of selected AC line cycleswhile in the self test mode in accordance with the predeterminedschedule, an automated self test circuit coupled to the control circuit,the automated self test circuit being configured to generate a simulatedsensor fault signal in response to the self test actuation signal, and amonitoring circuit coupled to the fault detection circuit and thecircuit interrupter assembly, the monitoring circuit being configured tomonitor the response of the sensor circuit, the fault detection circuitand at least one component of the circuit interrupter assembly duringthe selected AC line cycles and make an end-of-life determination basedon said response in accordance with predetermined noise immunizeddecision criteria, the monitoring circuit being further configured togenerate an end-of-life detection signal based on the predeterminednoise immunized decision criteria.
 2. The device of claim 1, wherein theautomatic self-test assembly includes at least one indicator configuredto emit an indication signal in response to the end-of-life detectionsignal.
 3. The device of claim 2, wherein the indication signal is avisual signal, an audible signal, or both.
 4. The device of claim 2,wherein the at least one indicator includes at least one light emittingelement.
 5. The device of claim 4, wherein the at least one lightemitting element is configured to emit a coded signal to indicate one ofa plurality of events.
 6. The device of claim 5, wherein the pluralityof events includes a plurality of failure modes, the plurality offailure modes including an open solenoid, a shorted solenoid, a shortedSCR, or an open SCR.
 7. The device of claim 5, wherein the plurality ofevents indicated includes an end-of-life state, a tripped state, or areset state.
 8. The device of claim 1, wherein the circuit interrupterassembly includes an SCR, at least one solenoid and a circuitinterrupter.
 9. The device of claim 8, wherein the circuit interrupteris a four-pole circuit interrupter that separates a plurality ofreceptacle load contacts from the plurality of line terminals and theplurality of load terminals in the tripped state.
 10. The device ofclaim 8, wherein the at least one solenoid includes a primary solenoidand a redundant solenoid.
 11. The device of claim 1, wherein thepredetermined half-cycle of the AC line cycle is a predeterminedhalf-cycle polarity of AC power.
 12. The device of claim 11, wherein thepredetermined half-cycle polarity of AC power is a negative polarity.13. The device of claim 1, wherein the automatic self-test assemblyincludes an automated switching mechanism disposed in the automated selftest circuit and configured to selectively introduce the simulatedsensor fault signal on the plurality of line terminals or the pluralityof load terminals.
 14. The device of claim 13, wherein the automatedswitching mechanism includes a relay coupled to a switch disposed on atest circuit.
 15. The device of claim 1, wherein the automatic self-testassembly includes a timing circuit coupled to the fault detectioncircuit and a test circuit coupled to the plurality of line terminals.16. The device of claim 1, wherein the predetermined periodic testingschedule includes scheduling the simulated sensor fault signal forselected negative half-cycles of the AC cycle.
 17. The device of claim1, wherein the predetermined periodic testing schedule includesscheduling the simulated sensor fault signal every negative half-cyclesof the AC cycle.
 18. The device of claim 1, wherein the end-of-lifesignal is generated in response to a plurality of failure modes, theplurality of failure modes including an open solenoid, a shortedsolenoid, a shorted SCR, or an open SCR.
 19. The device of claim 1,wherein the automatic self-test assembly includes at least one indicatorconfigured to signal an open solenoid, a shorted solenoid, a shortedSCR, or an open SCR.
 20. The device of claim 1, wherein the test resultsignal indicates a successful test when the fault detection signal isdetected, and indicates an unsuccessful test when the fault detectionsignal is not detected.
 21. The device of claim 1, wherein thepredetermined noise immunized decision criteria includes monitoring theresponse over a plurality of consecutive test cycles.
 22. The device ofclaim 1, wherein the predetermined noise immunized decision criteriaincludes monitoring the response over a span of at least one minute. 23.The device of claim 1, further comprising a by-pass circuit configuredto circumvent the control circuit and trip the circuit interrupterassembly when predetermined conditions occur.
 24. The device of claim23, wherein the predetermined conditions include a ground fault currentexceeding a predetermined amplitude.
 25. the device of claim 24, whereinthe predetermined amplitude is greater than or equal to about 100 mA.26. The device of claim 1, wherein the control circuit is configured todeactivate the automated self test circuit in the non-self test mode.27. The device of claim 1, wherein the control circuit is configured tobe in the non-self test mode during a predetermined non-self test modeduration in accordance with a predetermined schedule, the non-self testmode duration being selectable.
 28. The device of claim 27, wherein thenon-self test mode duration is within a range between one second and onemonth.
 29. The device of claim 1, wherein at least one conductive pathconnecting the plurality of line terminals and the plurality of loadterminals is interrupted in response to the end-of-life signal.
 30. Thedevice of claim 1, wherein the end-of-life detection signal includes anend-of-life indication signal and an end-of-life circuit interruptionsignal, the end-of-life indication signal being generated apredetermined time interval before the end-of-life circuit interruptionsignal.
 31. The device of claim 30, wherein the predetermined timeinterval is less than or equal to about twenty-four hours.
 32. Thedevice of claim 30, wherein the predetermined time interval is less thanor equal to about forty-eight hours.
 33. The device of claim 1, furthercomprising a signal conditioning circuit disposed between the faultdetection circuit, the circuit interrupting assembly and the monitoringcircuit, the signal conditioning circuit being configured to provide aconditioned signal input to the monitoring circuit.
 34. The device ofclaim 33, wherein the signal conditioning circuit includes a tankcircuit.
 35. The device of claim 34, wherein the tank circuit includes atrip solenoid, the trip solenoid being a portion of the circuitinterrupter assembly.
 36. The device of claim 33, wherein theconditioned signal input is indicative of whether the sensor circuit,the fault detection circuit, a power supply circuit, or the circuitinterrupter assembly are in a failed condition.
 37. The device of claim1, further comprising an end-of-life redundancy protection circuitconfigured to detect and respond to an end-of-life condition in at leastone component of the automatic self-test assembly.
 38. The device ofclaim 1, wherein the automated self test circuit is configured togenerate a simulated grounded neutral fault condition.
 39. The device ofclaim 1, wherein the fault detection circuit is configured to detect aground fault condition or an arc fault condition.
 40. The device ofclaim 1, further comprising a wiring state detection circuit coupledbetween the plurality of line terminals and the plurality of loadterminals, the wiring state detection circuit being configured tosubstantially prevent the circuit interrupter assembly from operating inthe reset state if a source of AC power is improperly connected to theplurality of load terminals.
 41. The device of claim 1, wherein thecircuit interrupter assembly includes redundant trip solenoids.
 42. Thedevice of claim 1, further comprising a power denial mechanism coupledto the plurality of line terminals and the plurality of load terminals,the power denial mechanism being configured to open circuit at least oneconductor disposed between the plurality of line terminals and theplurality of load terminals in response to the end-of-life detectionsignal.